ignition CHRYSLER CARAVAN 2003 Owner's Guide

OPERATION
The data link connector (diagnostic connector)
links the DRB scan tool with the Powertrain Control
Module (PCM). Refer to On-Board Diagnostics in the
General Diagnosis section of this group.
FRONT CONTROL MODULE
DESCRIPTION
The Front Control Module (FCM) is a micro con-
troller based module located in the engine compart-
ment. This FCM mates to the power distribution
center to form the Integrated Power Module (IPM).
The IPM connects directly to the battery and pro-
vides the primary means of circuit protection and
power distribution for all vehicle electrical systems.
The FCM controls power to some of these vehicle sys-
tems electrical and electromechanical loads based on
inputs received from hard wired switch inputs and
data received on the Programmable Communications
Interface (PCI) data bus.
For information on the IPM, (Refer to 8 - ELEC-
TRICAL/POWER DISTRIBUTION/INTEGRATED
POWER MODULE - DESCRIPTION)
OPERATION
As messages are sent over the Programmable Com-
munications Interface (PCI) data bus, the Front Con-
trol Module (FCM) reads these messages and controls
power to some of the vehicles electrical systems by
completing the circuit to ground (low side driver) or
completing the circuit to 12 volt power (high side
driver).
The following functions arecontrolledby the
Front Control Module:²Accessory Relay Actuation
²Brake Transmission Shift Interlock Functions
(BTSI)
²Diesel Cabin Heater (Diesel Engine Vehicles)
²Electronic Back Light (EBL) Rear Defogger
²Electronic Transaxle (Gasoline engine Vehicles)
²Front and Rear Blower Motor Relay Actuation
²Front Fog Lamp Relay Actuation
²Front Washer Motor
²Front Windshield Wiper ªHIº & ªLOº Relay
Actuation
²Front Windshield Wiper ªONº Relay Actuation
²Headlamp Power with Voltage Regulation
²Horn Relay Actuation
²Headlamp Washer Relay Actuation
²Name Brand Speaker (NBS) Relay Actuation
²Occupant Restraint Controller Voltage
²Park Lamp Relay Actuation
²Rear Washer Motor
²Side Airbag Voltage
The following inputs areReceived/Monitoredby
the Front Control Module:
²Ambient Temperature Sensing
²Back-Up switch
²Brake Fluid Level
²B+ Connection Detection
²Engine Crank Signal (Diesel Engine Vehicles)
²Horn Input
²Ignition Switch Start Only
²Ignition Switch Run and Start Only
²Stop Lamp Sense
²Washer Fluid Level
²Windshield Wiper Park
DIAGNOSIS AND TESTING - FRONT CONTROL
MODULE
The Front Control Module (FCM) is a printed cir-
cuit board based module with a on-board micro-pro-
cessor. The FCM interfaces with other electronic
modules in the vehicle via the Programmable Com-
munications Interface (PCI) data bus. In order to
obtain conclusive testing the PCI data bus and all of
the electronic modules that provide inputs to, or
receive outputs from the FCM must be checked. All
PCI communication faults must be resolved prior to
further diagnosing any front control module related
issues.
The FCM was designed to be diagnosed with an
appropriate diagnostic scan tool, such as the DRB
IIIt. The most reliable, efficient, and accurate means
to diagnose the front control module requires the use
of a DRB IIItscan tool and the proper Body Diag-
nostic Procedures manual.
Before any testing of the FCM is attempted, the
battery should be fully charged and all wire harness
Fig. 4 DATA LINK CONNECTOR
RSELECTRONIC CONTROL MODULES8E-7
DATA LINK CONNECTOR (Continued)
ProCarManuals.com

and ground connections inspected around the affected
areas on the vehicle.
REMOVAL
(1) Disconnect and isolate the negative and posi-
tive battery cables from the battery.
(2) Remove the battery from the vehicle. Refer to
the procedure in Battery Systems.
(3) Using a long flat-bladed screwdriver, gently
twist the Integrated Power Module (IPM) retaining
clip outboard to free the IPM from its mounting
bracket (Fig. 5). Rotate IPM upward to access the
Front Control Module (FCM) retaining screws.
(4) Remove the front control module retaining
screws.
(5) Using both hands, pull the FCM straight from
the IPM assembly to disconnect the 49-way electrical
connector (Fig. 6) and remove the front control mod-
ule from the vehicle.
INSTALLATION
NOTE: Front Control Module must be programmed
to the correct radio EQ curve using the DRB IIIT.
This will ensure that the audio system is operating
correctly.
(1) Install the Front Control Module (FCM) in the
Integrated Power Module (IPM) assembly by pushing
the 49-way electrical connector straight in.
(2) Install the FCM retaining screws. Torque the
screws to 1 N´m (7 in. lbs).
(3) Rotate the IPM assembly downward to secure
in mounting bracket.(4) Install the battery in the vehicle. Refer to the
procedure in Battery Systems.
(5) Connect the positive and negative battery
cables.
(6) Using the DRB IIIt, under ªFRONT CON-
TROL MODULEº then ªMISCº program the EQ
curve of the radio into the Front Control Module.
Refer to the appropriate diagnostic manual.
NOTE: If the vehicle is not equipped with Name
Brand Speakers (Infinity, etc.) or Headlamp Washers
the DRB IIITmust be used to Disable the appropri-
ate relays in the Integrated Power Module Assem-
bly.
HEATED SEAT MODULE
DESCRIPTION
Vehicles equipped with heated seats utilize two
heated seat modules. The heated seat modules (Fig.
7) are located under the front seats, where they are
secured to the seat cushion pans. The left heated
seat module controls the left heated seat, and the
right controls the right. Each heated seat module has
three connector receptacles that allow the modules to
be connected to all of the required inputs and out-
puts through the seat wire harness.
The heated seat modules are an electronic micro-
processor controlled device designed and programmed
to use inputs from the ignition switch, heated seat
Fig. 5 REMOVING INTEGRATED POWER MODULE
Fig. 6 FRONT CONTROL MODULE
1 - FRONT CONTROL MODULE
8E - 8 ELECTRONIC CONTROL MODULESRS
FRONT CONTROL MODULE (Continued)
ProCarManuals.com

NOTE: PCM Inputs:
²Air Conditioning Pressure Transducer
²Ambient temperature Sensor
²ASD Relay
²Battery Temperature Sensor (NGC)
²Battery Voltage
²Brake Switch
²Camshaft Position Sensor
²Crankshaft Position Sensor
²Distance Sensor (from transmission control mod-
ule)
²EGR Position Feedback
²Engine Coolant Temperature Sensor
²Heated Oxygen Sensors
²Ignition sense
²Intake Air Temperature Sensor
²Knock Sensor
²Leak Detection Pump Feedback
²Manifold Absolute Pressure (MAP) Sensor
²Park/Neutral
²PCI Bus
²Power Steering Pressure Switch
²Proportional Purge Sense
²SCI Receive
²Speed Control
²Throttle Position Sensor
²Torque Management Input
²Transaxle Control Module (3.3/3.8L Only)
²Transmission Control Relay (Switched B+) (2.4L
Only)
²Transmission Pressure Switches (2.4L Only)
²Transmission Temperature Sensor (2.4L Only)
²Transmission Input Shaft Speed Sensor (2.4L
Only)
²Transmission Output Shaft Speed Sensor (2.4L
Only)
²Transaxle Gear Engagement
²Vehicle Speed
NOTE: PCM Outputs:
²Air Conditioning Clutch Relay
²Automatic Shut Down (ASD) and Fuel Pump
Relays
²Data Link Connector (PCI and SCI Transmit)
²Double Start Override
²EGR Solenoid
²Fuel Injectors
²Generator Field
²High Speed Fan Relay
²Idle Air Control Motor
²Ignition Coils
²Leak Detection Pump
²Low Speed Fan Relay
²MTV Actuator
²Proportional Purge Solenoid²SRV Valve
²Speed Control Relay
²Speed Control Vent Relay
²Speed Control Vacuum Relay
²8 Volt Output
²5 Volt Output
²Torque Reduction Request
²Transmission Control Relay (2.4L Only)
²Transmission Solenoids (2.4L Only)
²Vehicle Speed
Based on inputs it receives, the powertrain control
module (PCM) adjusts fuel injector pulse width, idle
speed, ignition timing, and canister purge operation.
The PCM regulates the cooling fans, air conditioning
and speed control systems. The PCM changes gener-
ator charge rate by adjusting the generator field.
The PCM adjusts injector pulse width (air-fuel
ratio) based on the following inputs.
²Battery Voltage
²Intake Air Temperature Sensor
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)
²Exhaust Gas Oxygen Content (heated oxygen
sensors)
²Manifold Absolute Pressure
²Throttle Position
The PCM adjusts engine idle speed through the
idle air control motor based on the following inputs.
²Brake Switch
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)
²Park/Neutral
²Transaxle Gear Engagement
²Throttle Position
²Vehicle Speed
The PCM adjusts ignition timing based on the fol-
lowing inputs.
²Intake Air Temperature
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)
²Knock Sensor
²Manifold Absolute Pressure
²Park/Neutral
²Transaxle Gear Engagement
²Throttle Position
The automatic shut down (ASD) and fuel pump
relays are mounted externally, but turned on and off
by the powertrain control module through the same
circuit.
The camshaft and crankshaft signals are sent to
the powertrain control module. If the PCM does not
receive both signals within approximately one second
of engine cranking, it deactivates the ASD and fuel
pump relays. When these relays are deactivated,
power is shut off to the fuel injectors, ignition coils,
8E - 12 ELECTRONIC CONTROL MODULESRS
POWERTRAIN CONTROL MODULE (Continued)
ProCarManuals.com

OPERATION - SENSOR RETURN - PCM INPUT
The sensor return circuit provides a low electrical
noise ground reference for all of the systems sensors.
The sensor return circuit connects to internal ground
circuits within the Powertrain Control Module
(PCM).
OPERATION - DATA BUS COMMUNICATION
RECEIVE - PCM INPUT
The PCM uses the SCI communication bus to pre-
form engine diagnostics and flash operations. The
transmission side of the PCM uses the SCI commu-
nication bus to flash new software. However, diagnos-
tics is performed via the vehicles J1850 bus for the
transmission side of the PCM.
OPERATION - IGNITION SENSE - PCM INPUT
The ignition sense input informs the Powertrain
Control Module (PCM) that the ignition switch is in
the crank or run position.
OPERATION - PCM GROUND
Ground is provided through multiple pins of the
PCM connector. Depending on the vehicle there may
be as many as two different ground pins. There are
power grounds and sensor grounds.
The power grounds are used to control the ground
side relays, solenoids, ignition coil or injectors. The
signal ground is used for any input that uses sensor
return for ground, and the ground side of any inter-
nal processing component.
The PCM case is shielded to prevent RFI and EMI.
The PCM case is grounded and must be firmly
attached to a good, clean body ground.
Internally all grounds are connected together, how-
ever there is noise suppression on the sensor ground.
For EMI and RFI protection the housing and cover
are also grounded separately from the ground pins.
OPERATION
OPERATION - 8-VOLT SUPPLY - PCM OUTPUT
- SBEC CONTROLLER
The PCM supplies 8 volts to the crankshaft posi-
tion sensor, camshaft position sensor.
OPERATION - 5 VOLT SUPPLY - PCM OUTPUT
The PCM supplies 5 volts to the following sensors:
²A/C pressure transducer
²Ambient Temperature sensor
²Battery temperature
²Camshaft Position Sensor (NGC)
²Crankshaft Position Sensor (NGC)
²Electronic Throttle Control (1.6L)²Engine coolant temperature sensor
²Inlet Air Temperature Sensor
²Knock sensor
²Linear EGR solenoid (if equipped)
²Manifold absolute pressure sensor
²Oil Pressure Switch
²Pedal Position Sensor (1.6L)
²Throttle position sensor
²Vehicle Speed Sensor
STANDARD PROCEDURE
STANDARD PROCEDURE - OBTAINING
DIAGNOSTIC TROUBLE CODES
BULB CHECK
Key on: Bulb illuminated until vehicle starts, as
long as all once per trip (readiness) monitors com-
pleted. If monitors havenotbeen completed, then:
Key on: bulb check for about 5 to 8 seconds, lamp
then flashes if once per trip (readiness) monitors
havenotbeen completed until vehicle is started,
then MIL is extinguished.
OBTAINING DTC'S USING DRB SCAN TOOL
(1) Connect the DRB scan tool to the data link
(diagnostic) connector. This connector is located in
the passenger compartment; at the lower edge of
instrument panel; near the steering column.
(2) Turn the ignition switch on and access the
ªRead Faultº screen.
(3) Record all the DTC's and ªfreeze frameº infor-
mation shown on the DRB scan tool.
(4) To erase DTC's, use the ªErase Trouble Codeº
data screen on the DRB scan tool.Do not erase any
DTC's until problems have been investigated
and repairs have been performed.
STANDARD PROCEDURE - PINION FACTOR
SETTING
NOTE: This procedure must be performed if the
PCM/TCM has been replaced with a NEW or
replacement unit. Failure to perform this procedure
will result in an inoperative or improperly calibrated
speedometer.
The vehicle speed readings for the speedometer are
taken from the output speed sensor. The PCM/TCM
must be calibrated to the different combinations of
equipment (final drive and tires) available. Pinion
Factor allows the technician to set the Powertrain/
Transmission Control Module initial setting so that
the speedometer readings will be correct. To properly
RSELECTRONIC CONTROL MODULES8E-15
POWERTRAIN CONTROL MODULE (Continued)
ProCarManuals.com

Refer to the appropriate Powertrain Diagnostic Man-
ual and the DRBIIItscan tool.
(1) Install PCM module to the mounting bracket.
(2) Install electrical connectors and lock.
(3) Install the splash shield.
(4) Lower vehicle.
(5) Connect the negative battery cable.
(6) Using DRBIIItscan tool, program mileage and
vehicle identification number (VIN) into PCM. Refer
to the DRBIIItscan tool and the appropriate Power-
train Diagnostic Manual.
SENTRY KEY IMMOBILIZER
MODULE
DESCRIPTION
The Sentry Key Immobilizer Module (SKIM) con-
tains a Radio Frequency (RF) transceiver and a
microprocessor. The SKIM retains in memory the ID
numbers of any Sentry Key that is programmed to it.
The maximum number of keys that may be pro-
grammed to each module is eight (8). The SKIM also
communicates over the Programmable Communica-
tion Interface (PCI) data bus with the Powertrain
Control Module (PCM), the Body Control Module
(BCM), the Mechanical Instrument Cluster (MIC),
and the DRB IIItscan tool. The SKIM transmits and
receives RF signals through a tuned antenna
enclosed within a molded plastic ring formation that
is integral to the SKIM housing. When the SKIM is
properly installed on the steering column, the
antenna ring fits snugly around the circumference of
the ignition lock cylinder housing. If this ring is not
mounted properly, communication problems may
arise in the form of transponder-related faults.
For added system security, each SKIM is pro-
grammed with a unique9Secret Key9code. This code
is stored in memory and is sent over the PCI bus to
the PCM and to each key that is programmed to
work with the vehicle. The9Secret Key9code is there-
fore a common element found in all components of
the Sentry Key Immobilizer System (SKIS). In the
event that a SKIM replacement is required, the
9Secret Key9code can be restored from the PCM by
following the SKIM replacement procedure found in
the DRB IIItscan tool. Proper completion of this
task will allow the existing ignition keys to be repro-
grammed. Therefore, new keys will NOT be needed.
In the event that the original9Secret Key9code can
not be recovered, new ignition keys will be required.
The DRB IIItscan tool will alert the technician if
key replacement is necessary. Another security code,
called a PIN, is used to gain secured access to the
SKIM for service. The SKIM also stores in its mem-
ory the Vehicle Identification Number (VIN), which itlearns through a bus message from the assembly
plant tester. The SKIS scrambles the information
that is communicated between its components in
order to reduce the possibility of unauthorized SKIM
access and/or disabling.
OPERATION
When the ignition switch is moved to the RUN
position, the Sentry Key Immobilizer Module (SKIM)
transmits an Radio Frequency (RF) signal to the
transponder in the ignition key. The SKIM then
waits for a response RF signal from the transponder
in the key. If the response received identifies the key
as valid, the SKIM sends a9valid key9message to
the Powertrain Control Module (PCM) over the Pro-
grammable Communication Interface (PCI) data bus.
If the response received identifies the key as invalid
or no response is received from the transponder in
the ignition key, the SKIM sends an9invalid key9
message to the PCM. The PCM will enable or disable
engine operation based upon the status of the SKIM
messages. It is important to note that the default
condition in the PCM is9invalid key.9Therefore, if no
response is received by the PCM, the engine will be
immobilized after two (2) seconds of running.
The SKIM also sends indicator light status mes-
sages to the Mechanical Instrument Cluster (MIC) to
operate the light. This is the method used to turn the
light ON solid or to flash it after the indicator light
test is complete to signify a fault in the SKIS. If the
light comes ON and stays ON solid after the indica-
tor light test, this signifies that the SKIM has
detected a system malfunction and/or that the SKIS
has become inoperative. If the SKIM detects an
invalid keyORa key-related fault exists, the indica-
tor light will flash following the indicator light test.
The SKIM may also request an audible chime if the
customer key programming feature is available and
the procedure is being utilized (Refer to 8 - ELEC-
TRICAL/VEHICLE THEFT SECURITY/TRANSPON-
DER KEY - STANDARD PROCEDURE).
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove Lower Instrument Panel Cover. Refer
to Body, Instrument Panel, Lower Instrument Panel
Cover, Removal.
(3) Remove the steering column upper and lower
shrouds. Refer to Steering, Column, Column Shroud,
Removal.
(4) Disengage the steering column wire harness
from the Sentry Key Immobilizer Module (SKIM).
(5) Remove the one screws securing the SKIM to
the steering column.
8E - 18 ELECTRONIC CONTROL MODULESRS
POWERTRAIN CONTROL MODULE (Continued)
ProCarManuals.com

(6) Rotate the SKIM upwards and then to the side
away from the steering column to slide the SKIM
antenna ring from around the ignition switch lock
cylinder housing.
(7) Remove the SKIM from the vehicle.
INSTALLATION
(1) Slip the SKIM antenna ring around the igni-
tion switch lock cylinder housing. Rotate the SKIM
downwards and then towards the steering column.
(2) Install the one screws securing the SKIM to
the steering column.
(3) Engage the steering column wire harness from
the Sentry Key Immobilizer Module (SKIM).
(4) Install the steering column upper and lower
shrouds. Refer to Steering, Column, Column Shroud,
Installation.
(5) Install the Lower Instrument Panel Cover.
Refer to Body, Instrument Panel, Lower Instrument
Panel Cover, Installation.
(6) Connect the battery negative cable.
SLIDING DOOR CONTROL
MODULE
DESCRIPTION
Vehicles equipped with a power sliding door utilize
a sliding door control module. The sliding door con-
trol module is located behind the sliding door trim
panel in the center of the door, just above the sliding
door motor (Fig. 15). This module controls the opera-
tion of the door through the Programmable Commu-
nication Interface (PCI) J1850 data bus circuit and
the Body Control Module. The sliding door control
module contains software technology which enables it
to detect resistance to door travel and to reverse door
travel in order to avoid damage to the door or to
avoid possible personal injury if the obstruction is a
person. This feature functions in both the opening
and closing cycles. If the power sliding door system
develops any problems the control module will store
and recall Diagnostic Trouble Codes (DTC). The use
of a diagnostic scan tool, such as the DRB IIItis
required to read and troubleshoot these trouble
codes. The sliding door control module can be
reflashed if necessary. Refer to the latest Technical
Service Bulletin (TSB) Information for any updates.
The power door control module is a replaceable
component and cannot be repaired, if found to be
faulty it must be replaced. Consult your MoparŸ
parts catalog for a specific part number.
OPERATION
The power sliding door control module serves as
the main computer for the power sliding side doorsystem. All power door functions are processed
through the power door control module and/or the
vehicles body control module (BCM). At the start of a
power open command, a signal is sent to the BCM
and then to the power door control module via the
J1850 data bus circuit. This signal, generated by any
of the power door command switches, tells the power
door control module to activate a power latch release,
engage the clutch assembly and drive the door into
the full open position. If an obstacle is felt during
this power open cycle, the module will reverse direc-
tion and close the door. This process is also enabled
during a power close cycle. This process will repeat
three times, and if a fourth obstacle is detected, the
door will go into full manual mode. Once the full
open position is obtained, a hold open latch assembly
mounted full open switch tells the control module
that the door has reached the full open position. If
the power sliding door system develops any problems
the control module will store and recall Diagnostic
Trouble Codes (DTC). The use of a diagnostic scan
tool, such as the DRB IIItis required to read and
troubleshoot these trouble codes.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
Fig. 15 Power Side Door Components
1 - SLIDING DOOR CONTROL MODULE
2 - MODULE RETAINING SCREW
3 - MODULE ELECTRICAL CONNECTORS
4 - DOOR MOTOR ASSEMBLY
5 - FLEX DRIVE ASSEMBLY
6 - DOOR MOTOR RETAINING FASTENERS
7 - DOOR MOTOR ELECTRICAL CONNECTOR
RSELECTRONIC CONTROL MODULES8E-19
SENTRY KEY IMMOBILIZER MODULE (Continued)
ProCarManuals.com

(2) Remove the appropriate door trim panel from
the vehicle. Refer to Body for the procedure.
(3) Remove the weather shield. Refer to Body for
the procedure.
(4) Disconnect the power door control module elec-
trical connectors. Slide the red locking tab out (away
from module) and depress connector retaining tab,
while pulling straight apart.
(5) Remove the control module retaining screw
(Fig. 15).
(6) Remove the module from the vehicle.
INSTALLATION
(1) Position the control module and install the
retaining screw.
(2) Connect the control module electrical connec-
tors. Slide the locking tab into the locked position.
(3) Install the appropriate door trim panel on the
vehicle. Refer to Body for the procedure.
(4) Install the weather shield. Refer to Body for
the procedure.
(5) Connect the negative battery cable.
(6) Using an appropriate scan tool, check and
erase any power door control module diagnostic trou-
ble codes.
(7) Verify power door system operation. Cycle the
power door through one complete open and close
cycle.
TRANSMISSION CONTROL
MODULE
DESCRIPTION
On models equipped with the 2.4L Engine option,
the Transmission Control Module (TCM) is located
behind the left fender and is fastened with three
screws to three clips in the left frame rail forward of
the suspension (Fig. 16). Models equipped with the
3.3/3.8L Engine option utilize a Powertrain Control
Module (PCM) which incorporates TCM functionality.
OPERATION
The TCM is the controlling unit for all electronic
operations of the transaxle. The TCM receives infor-
mation regarding vehicle operation from both direct
and indirect inputs, and selects the operational mode
of the transaxle. Direct inputs are hardwired to, and
used specifically by the TCM. Indirect inputs origi-
nate from other components/modules, and are shared
with the TCM via the J1850 communication bus.
Some examples ofdirect inputsto the TCM are:
²Battery (B+) voltage
²Ignition ªONº voltage
²Transmission Control Relay (Switched B+)
²Throttle Position Sensor²Crankshaft Position Sensor (CKP)
²Transmission Range Sensor (TRS)
²Pressure Switches (L/R, 2/4, OD)
²Transmission Temperature Sensor (Integral to
TRS)
²Input Shaft Speed Sensor
²Output Shaft Speed Sensor
Some examples ofindirect inputsto the TCM
are:
²Engine/Body Identification
²Manifold Pressure
²Target Idle
²Torque Reduction Confirmation
²Speed Control ON/OFF Switch
²Engine Coolant Temperature
²Ambient/Battery Temperature
²Brake Switch Status
²DRB Communication
Based on the information received from these var-
ious inputs, the TCM determines the appropriate
shift schedule and shift points, depending on the
present operating conditions and driver demand.
This is possible through the control of various direct
and indirect outputs.
Some examples of TCMdirect outputsare:
²Transmission Control Relay
²Solenoids (LR/CC, 2/4, OD and UD)
²Vehicle Speed (to PCM)
²Torque Reduction Request (to PCM)
An example of a TCMindirect outputis:
²Transmission Temperature (to PCM)
Fig. 16 Transmission Control Module (TCM)
Location
1 - TRANSMISSION CONTROL MODULE (TCM)
8E - 20 ELECTRONIC CONTROL MODULESRS
SLIDING DOOR CONTROL MODULE (Continued)
ProCarManuals.com

ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM......................... 1
CHARGING.............................. 20STARTING............................... 28
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING - BATTERY
SYSTEM.............................2
CLEANING.............................5
INSPECTION...........................5
SPECIFICATIONS........................6
SPECIAL TOOLS
BATTERY SYSTEM SPECIAL TOOLS.......7
BATTERY
DESCRIPTION..........................7
OPERATION............................9
DIAGNOSIS AND TESTING - BATTERY.......9
STANDARD PROCEDURE
STANDARD PROCEDURE - SPIRAL PLATE
BATTERY CHARGING..................10
STANDARD PROCEDURE -
CONVENTIONAL BATTERY CHARGING.....11
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST.......................13
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST.........................13
STANDARD PROCEDURE - CHECKING
BATTERY ELECTROLYTE LEVEL.........14REMOVAL - BATTERY...................15
INSTALLATION.........................15
BATTERY HOLDDOWN
DESCRIPTION.........................15
OPERATION...........................15
REMOVAL.............................16
INSTALLATION.........................16
BATTERY CABLES
DESCRIPTION.........................16
OPERATION...........................16
DIAGNOSIS AND TESTING - BATTERY CABLE . 16
REMOVAL.............................18
INSTALLATION.........................18
BATTERY TRAY
DESCRIPTION.........................18
OPERATION...........................19
REMOVAL.............................19
INSTALLATION.........................19
THERMOWRAP
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................19
INSTALLATION.........................19
BATTERY SYSTEM
DESCRIPTION
A single 12-volt battery is standard factory-in-
stalled equipment on this model. All of the compo-
nents of the battery system are located within the
engine compartment of the vehicle. The battery sys-
tem for this vehicle covers the following related com-ponents, which are covered in further detail later in
this section of the service manual:
²Battery- The storage battery provides a reli-
able means of storing a renewable source of electrical
energy within the vehicle.
²Battery Cable- The battery cables connect the
battery terminal posts to the vehicle electrical sys-
tem.
RSENGINE SYSTEMS8F-1
ProCarManuals.com

BATTERY SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
THE BATTERY SEEMS
WEAK OR DEAD WHEN
ATTEMPTING TO START
THE ENGINE.1. The electrical system
ignition-off draw is excessive.1. Refer to the IGNITION-OFF DRAW TEST
Standard Procedure for the proper test
procedures. Repair the excessive ignition-off
draw, as required.
2. The charging system is
faulty.2. Determine if the charging system is performing
to specifications. Refer to Charging System for
additional charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
3. The battery is discharged. 3. Determine the battery state-of-charge using the
Micro 420 battery tester. Refer to the Standard
Procedures in this section for additional test
procedures. Charge the faulty battery, as
required.
4. The battery terminal
connections are loose or
corroded.4. Refer to Battery Cables for the proper battery
cable diagnosis and testing procedures. Clean
and tighten the battery terminal connections, as
required.
5. The battery has an
incorrect size or rating for
this vehicle.5. Refer to Battery System Specifications for the
proper size and rating. Replace an incorrect
battery, as required.
6. The battery is faulty. 6. Test the battery using the Micro 420 battery
tester. Refer to the Standard Procedures in this
section for additional test procedures. Replace
the faulty battery, as required.
7. The starting system is
faulty.7. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
8. The battery is physically
damaged.8. Inspect the battery for loose terminal posts or a
cracked and leaking case. Replace the damaged
battery, as required.
RSBATTERY SYSTEM8F-3
BATTERY SYSTEM (Continued)
ProCarManuals.com

BATTERY SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
THE BATTERY STATE OF
CHARGE CANNOT BE
MAINTAINED.1. The battery has an
incorrect size or rating for
this vehicle.1. Refer to Battery System Specifications for the
proper specifications. Replace an incorrect
battery, as required.
2. The battery terminal
connections are loose or
corroded.2. Refer to Battery Cable for the proper cable
diagnosis and testing procedures. Clean and
tighten the battery terminal connections, as
required.
3. The electrical system
ignition-off draw is excessive.3. Refer to the IGNITION-OFF DRAW TEST
Standard Procedure for the proper test
procedures. Repair the faulty electrical system, as
required.
4. The battery is faulty. 4. Test the battery using the Micro 420 battery
tester. Refer to Standard Procedures for
additional test procedures. Replace the faulty
battery, as required.
5. The starting system is
faulty.5. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
6. The charging system is
faulty.6. Determine if the charging system is performing
to specifications. Refer to Charging System for
charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
7. Electrical loads exceed the
output of the charging
system.7. Inspect the vehicle for aftermarket electrical
equipment which might cause excessive electrical
loads.
8. Slow driving or prolonged
idling with high-amperage
draw loads in use.8. Advise the vehicle operator, as required.
THE BATTERY WILL NOT
ACCEPT A CHARGE.1. The battery is faulty. 1. Test the battery using the Micro 420 battery
tester.. Charge or replace the faulty battery, as
required.
ABNORMAL BATTERY DISCHARGING
Any of the following conditions can result in abnor-
mal battery discharging:
1. A faulty or incorrect charging system compo-
nent. Refer to Charging System for additional charg-
ing system diagnosis and testing procedures.
2. A faulty or incorrect battery. Use Micro 420
tester and refer to Battery System for additional bat-
tery diagnosis and testing procedures.
3. A faulty circuit or component causing excessive
ignition-off draw.
4. Electrical loads that exceed the output of the
charging system. This can be due to equipmentinstalled after manufacture, or repeated short trip
use.
5. A faulty or incorrect starting system component.
Refer to Starting System for the proper starting sys-
tem diagnosis and testing procedures.
6. Corroded or loose battery posts and/or terminal
clamps.
7. Slow driving speeds (heavy traffic conditions) or
prolonged idling, with high-amperage draw loads in
use.
8F - 4 BATTERY SYSTEMRS
BATTERY SYSTEM (Continued)
ProCarManuals.com